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USING IRON ORE WASTE AS AGGREGATE IN MAKING

K. 300 QUALITY CONCRETE

Rajiman*1, Muhammad Amin2, Harjianto Setiaji3


1
Bandar Lampung University
2
Mineral Technology Research of Indonesian Institute of Sciences – LIPI
3
Sang Bumi Ruwa Jurai University
Korespondensi: rajimanmt@gmail.com

ABSTRACT

The main component of concrete is cement, water, and aggregate (fine and rough aggregate), with aggregate
constituting between 50% and 60% of total volume. Iron stone coming from nature is a material alternative
that can be used as rough aggregate in making concrete. This research was conducted by sieving iron ores with
sieving particle sizes of 2mm, 2-5 mm, 5-8 mm, and 10-12 mm. The compressive strength test was conducted
at 7, 14, and 28 days. The iron ore waste from iron processing can be used as aggregate for K 300 quality
concrete because the concrete compressive test result after 28 days by using sieving particle sizes of mesh 20,
mesh 5, mesh 8-10, and mesh 10-12 exceeded normal K 300 quality concrete with compressive strength scores
of 30.12 MPa, 38.90 MPa, 36.75 MPa, and 32.10 Mpa respectively, while normal K 300 quality concrete had
28.86 MPa compressive strength.

Keywords: Aggregate, compressive strength, concrete, iron ore, material

1. INTRODUCTION Integrated Office for Investment and Service of


Concrete is a composite building material Lampung province showed that concerning
made from a combination of aggregate and natural resource in Lampung, andesite stone
bonding cement. It is a composite material made mining in Lampung reached 1,980,000,000 m3
from aggregate bonding with liquid cement that in 2017 and the production has been increasing
is hardening overtime [1]. Concrete main so that andesite stone deposit is decreasing.
components are cement, water, and aggregate Therefore, alternative replacements for andesite
(fine and rough aggregate) with aggregate stone as rough aggregate in making concrete are
constituting between 50% and 60% of total required.
volume. Aggregate is the most mined material Iron ore coming from nature is one of
in the world and natural mineral particles alternative materials that can be used as rough
function as filing material in the mix of cement aggregate in making concrete beside stone.
or mortar [2]. Aggregate is responsible for unit According to Balance of Metal and Non-metal
weight, modulus elasticity and stability of Mineral Natural Sources from Geology
concrete dimension because these Resource Center in 2008, the primary iron ore
characteristics depend on aggregate physical source in Indonesia was 3,257,171,469 tons and
characteristics (strength and bulk density) [3]. reserve deposit of 87,228,005 tons.
The common rough aggregate in making There was a research [5] on becoming
concrete comes from andesite stone grinded laterite iron ore as find aggregate to replace sand
with stone crusher and differentiated based on with the aggregate sizes of 19.5 mm, 12.5 mm,
its sizes. The andesite stone currently is used 9.5 mm, 5.0 mm, and 2.36 mm with 1:2:4 ratio
widely as aggregate for construction sector, composition (cement : laterite iron ore : granite)
especially infrastructures for roads, bridges, and water-cement ratio of 0.6. The iron ore
buildings, and other facilities [4], but andesite replaced sand by 25% and 50%. The testing
stone deposit is continuously decreasing result showed that 25% laterite content mixture
because of continuous production. Reports of by using rough aggregate sizes of 19.5 mm and

REKAYASA SIPIL / Volume 14. No.1 – 2020 ISSN 1978 - 5658 10


12.5 mm showed slum scores of 80 mm and 65 to use were differentiated based on their types;
mm. It indicated that more water was needed for type A = 5-15 mm, type B = 15-25 mm, and type
smaller sizes of rough aggregate to obtain c = 25-50 mm. The compressive strength test
medium work capability because of their surface was conducted at 21 days and the highest result
width. However, for rough aggregate with 2.36 was obtained by using basalt stone aggregate.
mm, 5.0 mm, and 2.36 mm with 50% laterite They were 24.74 MPa for type A, 21.20 MPa for
content, the slum score decreased to 0 mm, and type B, and 20.70 MPa for type C. The smallest
this showed a rigid consistence because of compressive strength was obtained by using
laterite iron ore affinity for water and because of lime stone at 8.58 MPa for type C. [8]
wider surface wide related to smaller particle
size of the rough aggregate. The compressive 2. RESEARCH METHOD
strength result showed that the concretes were This research used literary study and
all normal with all granite particle sizes experiment methods. Literary study method was
including 0% of laterite content with a peak used to see references related to this research,
compressive strength of 16 N/mm2 at 7 days and while experiment method was done by
24.44 N/mm2 at 28 days. Meanwhile, the preparing research materials in forms of iron
concrete with maximum laterite content of 50% ores, sand, and cement. Iron sand was sieved
produced minimum strength of 14.2 N/mm2 at 7 according to desired particle sizes: passing sizes
days and 20.00 N/mm2 at 28 days. This of 2 mm, 2 mm, 5 mm, 8-10 mm, and 10-12 mm.
indicated that the compressive strength Sieved iron ores were mixed with sand, cement,
decreased along with increasing laterite content and water and then concrete cube samples for
in the concrete [5]. testing were made with 150 x 150 x 150 mm
A research on using hematite iron ore as dimension. The reserachesign used iron ore
aggregate with maximum particle size of 20.0 waste as aggregate in making concrete.
mm with mixture of cement, sand, made into
concretes of 150 x 150 x 150 mm size and tested 2.1. Materials and Equipment
at 7, 28, and 56 days, produced 28.1 N/mm2 Equipment in this research were Gold
compressive strength at 7 days, 49.7778 28.1 series ohaus brand digital scale, memmert brand
N/mm2 at 28 days, 53.926 28.1 N/mm2 at 56 oven, pyrex 25 mL measuring cup, Pyrex 50 mL
days, and porosity 2.19% at 28 days [6]. A pycnometer, 1 set of multilevel siever, Wykeham
research on characteristics of concrete mixed Farrance Engineering brand compressive
with iron ore tailings or material coming from strength test machine made in England model
iron ore processing waste in form of granules 55104 with capacity of 1500 kN, pH indicator,
that are mixed into the concrete to replace bucket, spatula, gloves, concrete mixer, beaker
natural sand with concentration of 0%, 25%, glass, Pyrex made in Thailand (500 mL, 100
35%, and 45%. The concrete slum test result mL, 50 mL), 15cm x 15cm cube molding, Five
showed that the more iron ore waste was added, Goat brand analog scale made in China with
then the slump score would be lesser. The capacity of 5 kg, Sartorius brand analytic
compressive strength test result of concrete with weighing balance, XRF device, and SEM-EDS
150 x 150 x 150 mm cube size showed that the device. Materials in this research were Portland
longer the sample age, then the stronger the Cement Composite type I produced by PT.
compressive strength would be. The Semen Padang Indonesia, water from laboratory
compressive strength in 3 days was 17 MPa at of chemical and non-metal analysis from
0%, 15 MPa at 25%, 17 MPa at 35%, and 14 Mineral Technology Research office (BPTM) in
MPa at 45%. The compressive strength in 7 days South Lampung district, iron ores and sand from
was 27 MPa at 0%, 26.5 MPa at 25%, 28 MPa Tanjung Bintang.
at 35%, and 25 MPa at 45%. The compressive
strength in 28 days was 40 MPa at 0%, 39 MPa 2.2. Experiment Procedure
at 25%, 41 MPa at 35%, and 38 MPa at 45% [7]. The procedure of mortar making was as
There was a research on making K 200 follows. Preparing iron ore waste material, and
concrete with w/c ratio = 0.61 by using materials then it was sieved by the following particle
from Lampung as aggregates; they were lime sizes; passing 2 mm, 2 mm, 8-10 mm, and 10-
stone, feldspar stone, basalt stone, granite stone, 12 mm. Each of them was chemically analyzed
and slag from iron ore smelting. The aggregates by using XRF. Prparing concrete making

REKAYASA SIPIL / Volume 14. No.1 – 2020 ISSN 1978 - 5658 11


materials; sand, water, Portland cement However, PCC cement is a type of cement
composite type I produced by PT. Semen that is widely used for building housing. Bridge,
Padang Indonesia, and iron ore according to office, etc., but this PCC cement is not
their respective particle sizes. Scaling each recommended for high multilevel buildings
material with composition ratio based on SNI because its quality is lower than OPC type, that
03-2834-2000 for K 300 quality and can be used for all types of constructions and
water/cement ratio or FAS = 0.52, with the infrastructures. This is because CaO content is
following respective composition; 413 kg of very influential in cement when it reacts with
portland cement, 681 kg of sand, 1021 kg of water to create Calcium Silicate Hydrate (CSH),
gravel or iron ore aggregate, 215 liter of water. and the use of lime stone accelerates CSA
If the mix was made in 10 kg, the composition cement hydration [9]. Pelletier-Chaignat et.al.
would be 1.773 kg of cement, 2.922 kg of sand, suggest that the use of lime stone would be more
4.382 kg of aggregate, and 0.923 liter of water. effective in improving CSA cement strength
The concrete mixture from respective compared to quartz powder [10].
composition was stirred by using concrete
mixer. Mixing was done evenly for ± 15 minutes Table 1. Cement type PCC and OPC testing
followed by watering into the concrete mixture results
with an objective to make the composition soft No. Chemical Type PCC Type OPC
composition type (%) (%)
to reduce cracking. The mix was then tested with 1. Silicon Dioxide 23,13 18,69
slump test. The mix was poured into molding (SiO2)
device with 15 cm x 15 cm x 15 cm size while 2. Aluminum Oxide 8,76 5,00
(Al2O3)
stabbed repeatedly by using taper iron stick to 3. Ferro Oxide (Fe2O3) 4,62 3,49
make the mix evenly filling the mold and then it 4. Calcium Oxide (CaO) 58,66 63,12
was left aside for 24 hours from the time it was 5. Magnesium Oxide 0,90 1,09
(MgO)
molded. The testing object was entered into a 6. Sulfur Trioxide (SO3) 2,18 2,95
water container for wet curing. Water 7. Loss on ignition 1,69 3,56
temperature was set to be room temperature at (LOI)
8. Free lime 0,69 1,27
230 to 320C.the compressive strength test was 9. Undissolved part 8,82 0,36
done by using standard of ASTM C 39-86
(1993) at 7, 14, and 28 days. The concrete then The XRF analysis result of iron ore
was tested physically and chemically with material as aggregate according to its respective
compressive strength test, absorption test, particle size can be seen in Table 2. Iron ore is
specific gravity test, and XRF chemical a mineral coming from nature that is dominated
analysis. by iron element and other impurity elements.
Iron ore can be used as aggregate. Based on
3. RESULT AND DISCUSSION XRF testing result, Table 2 shows that sthe
3.1. The Raw Material Testing bigger the aggregate size, then the higher the Fe
Cement type PCC and OPC testing results content will be. The Fe content is 38.246% for <
by using can be seen in Table 1. Table 1 shows 2mm aggregate size, 47.460% for 2-5 mm size,
that CaO compound content at PCC cement is 49.330% for 5-8 mm size, 58.660% for 8-10
58.66%, and it is lesser than at OPC cement mesh aggregate and 69.225% for 10-12 mesh
(63.12%). CaO in cement is a dominant element aggregate. The bigger is the aggregate size, then
coming from lime stone raw material. The Cao the higher is the Fe content. The bigger
content is very influential to the drying speed of aggregate contains lower soil content at the iron
the cement mix or concrete. The higher is the ores or is cleaner, so that the iron ore is more
CaO content, then the faster would be the drying dominated by Fe. Soil existence at aggregate
process. The use of lime stone can also improve contaminate cement and it influences cement
sustainability of building material and reduce strength. A research result shows that soil
clinker component that consumes the most addition to cement can also improve cement
energy and produces the most CO2 during strength provided at particular soil amount
manufacture process [9]. added at drying and certain contamination
amount [11].

REKAYASA SIPIL / Volume 14. No.1 – 2020 ISSN 1978 - 5658 12


Table 2. Iron ore aggregate XRF testing result strength [13]. The slump content also meets the
Aggregate size (mm) standard by 4.56%, while the standard is below
Chemical
element 5%. It is because the sand coming from the
<2 2-5 5-8 8 - 10 10 - 12
beach is by sucking method has already be clean
Fe 38,346 47,460 49,330 58,660 69,225
because of mixed with water, so that the sand is
Si 3,847 5,216 3,567 5,788 1,416 free from excessive slump content. The good
K 2,528 2,211 3,500 1,554 1,317 aggregate must be strong, durable, and clean.
Al 1,372 2,163 1,640 2,444 1,875 The excessive slump and other impurity particle
Cl 1,525 1,185 1,319 1,295 - contents shall reduce bonding between cement
Ca 0,406 0,878 - - - paste and its aggregate. Aggregate strength
Mg - - 6,198 7,901 -
provides an important influence to concrete
strength and the characteristics of an aggregate
Ti - - - - 1,065
shall influence concrete durability and strength
S - - - - 0,864
[14].
Rough aggregate can be produced from
The sand to use in this research came nature and artificially. Coral stone is an example
from Pasir Sakti village, Labuhan Maringgai of of natural rough aggregate. Artificial rough
East Lampung district. The physical testing aggregate can be produced from andesite stone
result of Labuhan Maringgai sand can be seen in crushing and limestone. This research used iron
Table 3. ore from Karnataka, India, as the rough
aggregate that has the following chemical
Table 3. The physical testing result of sand as composition; Fe = 63.84%, SiO2 = 2.64%, Al2O4
fine aggregate = 3.98 %, CaO = 0.14%, and MgO = 0.08%. The
No. Test Percen Stand Descriptio reason to select iron ore as the rough aggregate
tage ard n
1. Sand gradation 2.3 2.2 - qualified was that because it had irregular shape, rough
(fine granular 3.2 and sharp surface, durable against wheatear and
modulus)
2. Specific gravity 2.03 - Mild
indestructible, high hardness index by 5.5-6.5
g/cm3 aggregate Mohs scale, and gradation resistance [15]. The
3. Slump content 4.56 % ≤5% qualified iron ore testing result and material requirements
4. Water content 0.45 % - acceptable
humidity
as rough aggregate based on ASTM C35-37 can
5. Sand absorption 6% 13.27 qualified be seen in Table 4.
% Table 4 shows that slump content of iron
(Max.)
ore aggregate with sizes less than 2 mm and 2-5
mm exceed required threshold, while for 5-8
Table 3 shows the sand testing result as mm, 8-10 mm, and 10-12 mm sizes still satisfy
fine aggregate. The sand from Labuhan the requirement. It is because finer iron ore
Maringgai belongs to fine sand with 2.3 fine aggregate will be mixed with fine soil that enter
granular modulus (FGM) and it satisfies a into aggregate pores, so that when the aggregate
standard of becoming fine aggregate in concrete is washed, soil will be cleansed by water as
making. The sand granule size distribution slump. Bigger size aggregate contain less
influences mortar strength. When the granule attached soil, so that not much soil enter into
has uniform size, then sand pore volume will be aggregate pores and lesser soil will be cleansed
bigger. Oppositely, when the sand granule size by water and the slump content will be lower.
varies, sand pore volume will be lower. This is The slump content is very influential at the
because smaller size granules will fill pores concrete making process, because much more
between bigger granules, so that the pores will slump content will cause concrete cracks. It also
be lesser (high density) [12]. Aggregate fineness influences absorbed water content at the
or roughness can influence concrete aggregate, because the more slump content at
workability. If there is too much fine aggregate the aggregate will make more water absorbed by
in the concrete, it will cause thin layer of fine the slump, while the more aggregate water
aggregate and cement will rise up influencing absorption will cause longer time for concrete
the cement reactivity, so that it will be very drying.
suitable to be fillers, to reduce initial porosity of
the mixture and to improve concrete final

REKAYASA SIPIL / Volume 14. No.1 – 2020 ISSN 1978 - 5658 13


Table 4. Physical testing result of iron ore base on aggregate size
Aggregate testing Iron ore aggregate size (mm) ASTM C 35-37
<2 2-5 5-8 8 - 10 10 - 12
Specific gravity (g/cm3) 2.35 2.51 2.55 2.59 2.63 2.5 – 2.7
Slump content (%) 13.09 9.93 3.09 0.41 0.11 Max. 5
Water absorption (%) 23.19 21.86 6.42 5.49 3.37 2-7
Solid volume weight 2.43 2.61 2.67 2.72 2.76 >1.2

3.2. Concrete Product Testing Result [20]. Smaller aggregate size will have wider
3.2.1 The concrete slump testing (based on surface area and bigger friction, and will require
SNI 1972: 2008) more water, and the mix becomes rigid while
The objective of slump testing is to find temperature and mixing speed also influence the
out the concrete mix thickness and workability. slump score [21]. Table 4 shows that concrete
It is related to whether water mixed into with aggregate sizes < 2mm, 2-5 mm, 5-8 mm,
concrete mix is either too watery or not. Too 8-10 mm, and 10-12 mm have slump scores of
much water mixed into the concrete will 1.2 mm, 1.7 mm, 2.1 mm, 2.3 mm and 2.5 mm
influence concrete strength and longer drying respectively. All of them satisfy the requirement
time. The concrete slump testing result can be standard for road and foundation construction
seen in Table 5. (slump score for road = 0-25 mm; slumps score
for foundation = 10-40 mm). Meanwhile,
Table 5. Concrete slump testing based on iron according to ACI standard, only concrete with
ore aggregate sizes aggregate size of 10-12 mm with slump score 25
No. Aggregate size (mm) Slump test result mm will satisfy ACI standard. Concrete
(cm)
1. <2 1.2 compressive strength test (ASTM C 579-01,
2. 2-5 1.7 2001).
3. 5-8 2.1 The objective of concrete compressive
4. 8 – 10 2.3
5. 10 - 12 2.5
strength is to find out the magnitude of load per
width unit before finally the testing object be
The slump scores according to aggregate crushed by a particular load produced by
sizes in Table 5 indicate that the higher is the compressive strength machine. The
aggregate size, then the higher will be the slump compressive strength test result for the concrete
score or in other words the bigger concrete using iron ore aggregate can be seen in Table 6.
decadence score measured by Abrams device. In
addition, other factors that influence slump Table 6. The compressive strength test result of
score are aggregate type, aggregate size, concrete based on iron ore aggregate
aggregate absorption, water amount or water sizes
Compressive strength test
ratio compared to cement, and whether No. Aggregate size result (MPa)
aggregate surface is smooth or rough [16]. The (mm) 7 days 14 days 28 days
age age age
higher is the aggregate size, then the higher the 1. <2 21.73 26.82 30.12
slump score. It is caused by the aggregate 2. 2-5 28.18 32.44 38.90
granule gradation changes that influence 3. 5-8 26.21 31.98 36.75
concrete workability. Bigger aggregate granule 4. 8 – 10 25.26 29.36 35.66
will produce higher workability, because bigger 5. 10 - 12 22.77 26.89 32.10
6. Standard for 18.49 22.74 28.86
granule tends to have smaller friction, so that the normal
same composition will need more water, the mix concrete
becomes more watery. A concrete mix with
smaller aggregate size will have wider surface Table 6 shows concrete with bigger size
area with greater friction, so that it will make of iron or aggregate will have lower
more rigid mix [17], and this will influence compressive strength score compared to the one
concrete decadence score [18]. The bigger using smaller size of iron ore aggregate. It is
aggregate size require lesser water [19] so that it because the influence of aggregate size
will proportionate with the fresh concrete gradation to concrete density and porosity
workability with constant cement/water ratio levels. A good gradation shall produce

REKAYASA SIPIL / Volume 14. No.1 – 2020 ISSN 1978 - 5658 14


maximum density and minimum porosity. wider pores that influence the concrete density.
Aggregate gradation role is a factor that must be Because, while cement is binding aggregate
consider. A good gradation is the continuous granules, some aggregate are left unbound, so
gradation where all granule sizes in an aggregate that they create pores that create concrete pores
will create heterogenic granules. Heterogenic [23][24]. Cavities in the concrete are caused by
granules shall mutually filling empty pores air bubbles created during concrete molding.
according to their respective sizes [17]. Table 6 These bubbles is created by excessive water use,
shows that concrete with aggregate size < 2 mm or by bigger water ratio than cement. These
has compressive strength of 21.73 MPa, while excessive water will use some concrete spaces
concrete with aggregate size of 2-5 mm has an and when the concrete has dried and hardened,
increased compressive strength score of 28.18 it will leave concrete cavities and finally the
MPa. However, the scores decrease at concretes concrete is less dense. This influences the
with aggregate sizes of 5-8 mm, 8-10 mm, and concrete compressive strength. The
10-12 mm by 26.21 MPa, 25.26 MPa, and 22.77 water/cement ratio used in this research was in
MPa respectively at 7 days. Nevertheless, their normal limit by 0.52, so that the produced
compressive strength scores are stronger than compressive strength scores were still above
standard concrete with compressive strength of compressive strength of normal concrete by
18.49 MPa. The bigger is the concrete aggregate 18.49 MPa at 7 days, 22.74 MPa at 14 days, and
size, then the lower is the concrete compressive 28.86 MPa at 28 days. The bigger is the
strength, and vice versa [19]. It also applies with aggregate size, then the lower is the compressive
concrete ages at 14 and 28 days. Besides strength score [20].
aggregate size, the concrete age also influence
concrete compressive strength. The longer is the 3.3. Concrete Porosity Test (SNI 1969-2008)
concrete age for testing, then the higher is the The objective of concrete porosity test is
concrete compressive strength. This is to find out the amount of water absorbed by
influenced by hydration reaction occurring the concrete. This is influenced by cavities inside
cement. The compressive strength scores of 14 the concrete. The more pores in concrete will
days concrete age according to aggregate sizes cause wider surface width, and the more water
in order are the following; 26.82 MPa at < 2 mm will be absorbed. This is caused by incorrect
aggregate size, 32.44 MPa at 2-5 mm aggregate material composition and quality in concrete
size, 31.98 MPa at 5-8 mm aggregate size, 29.36 making. The concrete porosity scores according
MPa at 8-10 mm aggregate size, and 26.89 MPa to aggregate sizes are presented in Table 7.
at 10-12 mm; while standard concrete
compressive strength is 22.79 MPa at testing Table 7. Concrete porosity test result according
after 14 days. The compressive strength scores to aggregate sizes at 28 days
of 28 days concrete age according to aggregate No. Aggregate sizes (mm) Absorption test result
(%)
sizes in order are the following; 30.12 MPa at < 1. < 2 5.70
2 mm aggregate size, 38.90 MPa at 2-5 mm 2. 2-5 3.65
aggregate size, 36.75 MPa at 5-8 mm aggregate 3. 5-8 5.78
4. 8 – 10 6.46
size, 35.66 MPa at 8-10 mm aggregate size, and 5. 10 - 12 7.12
32.10 MPa at 10-12 mm; while standard 6. Normal concrete 7.24
concrete compressive strength is 28.86 MPa at
testing after 28 days. The concrete compressive Table 7 shows that the highest concrete
strength improvement by using iron are porosity score by 7.12% against water is obtain
aggregate is because iron ore particle density by the concrete using aggregate size of 10-12
can reduce concrete porosity, so that when mm. Other concrete porosity scores by using
soaking maintenance is done, it will improve γ- aggregate sizes of mesh 2-5, mesh 5-8, mesh 8-
ray [22]. In addition, concrete porosity is also 10 and mesh 10-12 are increasing at 3.65%,
related to concrete absorption score. The higher 5.78%, 6.46% and 7.12% respectively. Porosity
is the concrete porosity, then the higher is the score of concrete using aggregate size of mesh
water absorption. Concrete porosity and 20 is higher (5.70%) compared to the concrete
absorption are also influenced by aggregate using aggregate size less than mesh 20. Concrete
sizes that finally affect the compressive porosity score increases along with bigger
strength. The bigger aggregate size will have aggregate size, because aggregate size influence

REKAYASA SIPIL / Volume 14. No.1 – 2020 ISSN 1978 - 5658 15


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